Cumene hydroperoxide cleavage process

Abstract

A process for the decomposition of cumene hydroperoxide to phenol, acetone, and alpha-methylstyrene is presented. In this process, cumene hydroperoxide and sulfuric acid are reacted in a reflux cooled reactor the products of which are transported under inhibited conditions to a plug flow reactor, and are reacted to produce phenol, acetone, and alpha-methylstyrene. In one embodiment of the invention, a heat exchanger is used to obtain and maintain the inhibited conditions of the transported reactor products.

We claim as our invention 
     
       1. A process for the decomposition of cumene hydroperoxide to phenol, acetone, and alphamethylstyrene comprising: reacting cumene hydroperoxide and sulfuric acid in a reflux cooled reactor,   transporting the reaction products of the reflux cooled reactor under inhibited conditions to a plug flow reactor,   reacting the reaction products of the reflux cooled reactor in the plug flow reactor to produce phenol, acetone, and alpha-methylstyrene, and   recovering a member of the group consisting of phenol, acetone, alpha-methylstyrene, and mixtures thereof.   
     
     
       2. The process of claim 1 wherein said transportation step is isothermal. 
     
     
       3. The process of claim 1 wherein said transportation step is accompanied by a loss of heat. 
     
     
       4. The process of claim 1 wherein said transportation step occurs through an inhibitive zone. 
     
     
       5. The process of claim 4 wherein said inhibitive zone comprises a heat exchanger. 
     
     
       6. The process of claim 4 wherein a portion of said reflux cooled reactor products are transported through said heat exchanger and then recirculated into the reflux cooled reactor product being transported from said reflux cooled reactor before entering said plug flow reactor. 
     
     
       7. The process of claim 6 wherein said recirculated products of said reflux cooled reactor are recirculated to a point proximate to the exit point of said reflux cooled reactor. 
     
     
       8. The process of claim 6 further comprising the step of adding a severity inhibitor to said reflux cooled reactor products. 
     
     
       9. The process of claim 8 wherein said severity inhibitor comprises water. 
     
     
       10. The process of claim 9 wherein up to about 3% wt (based on weight of total reflux cooled reactor products) water is added to said reflux cooled reactor products. 
     
     
       11. The process of claim 8 wherein said severity inhibitor comprises acetone. 
     
     
       12. The process of claim 11 wherein up to 20% wt (based on total reflux cooled reactor products) acetone is added to said reflux cooled reactor products. 
     
     
       13. The process of claim 1 wherein a pump assists the transport of said reflux cooled reactor products to said plug flow reactor. 
     
     
       14. The process of claim 13 wherein the temperature of said reflux cooled reactor products at said pump is less than or equal to the temperature of the exit point of the reflux cooled reactor. 
     
     
       15. The process of claim 1 further comprising the step of adding water to said reflux cooled reactor. 
     
     
       16. The process of claim 15 wherein up to about 3% wt (based on total reflux cooled reactor products) of water is added to said reflux cooled reactor. 
     
     
       17. The process of claim 1 further comprising the step of adding acetone to said reflux cooled reactor. 
     
     
       18. The process of claim 17 wherein up to about 20% wt (based on total reflux cooled reactor products) of acetone is added to said reflux cooled reactor.